Patent GB-861156-A (GB)
Title: Foamed phenolic resinous materials
Inventor: DARRALL ROBERT ALFRED
IPC: C08L61/10
Filed: 1958-03-26
Abstract: Foamed resinous materials are prepared by mixing a liquid alkali-catalysed phenolic condensate of formaldehyde in which the phenolic component consists of a methyl-substituted monohydric phenol or mixture of such substituted phenols or a dihydric phenol carrying hydroxyl groups as sole substituents and which phenolic component may contain a minor amount (i.e. less than 50%) of phenol, with a sulphon-hydrazide and an acid-curing catalyst. The condensate preferably has a viscosity of 10-100 poises at 25 DEG  C.  The catalysts may be combined with the sulphonhydrazides to form salts which are then added to the condensate.  The foamed products may be used as packaging, insulating and reinforcing materials.  In the Examples: (1) and (2) a mixture of m-cresol formaldehyde, an alkyl phenol/ethylene oxide condensate and benzene sulphonhydrazide acid sulphate is used; (3) as (1) and (2) but also containing benzene sulphonhydrazide sulphate; (4) benzene sulphonhydrazide acid sulphate is added to a mixture of m-cresol formaldehyde and phenol formaldehyde; (5) 53% m-cresol formaldehyde (prepared from a coal-tar fraction containing 53% m-cresol, the remainder being p- and o-cresol and xylenols) is mixed with benzene sulphonhydrazide acid sulphate; (6) and (15) as (5) but also containing an alkyl phenol/ethylene oxide condensate and HCl; (7) a mixture of 53% m-cresol formaldehyde, an alkyl phenol/ethylene oxide condensate and p : p1-oxy-bis-(benzene sulphonhydrazide) acid sulphate is used; (8) phenol 53% m-cresol formaldehyde is mixed with benzene sulphonhydrazide acid sulphate; (9) as (8) but also incorporating an alkyl phenol/ethylene oxide condensate; (10) a mixture of phenol 53% m-cresol formaldehyde, an alkyl phenol/ethylene oxide condensate and benzene sulphonhydrazide p-toluene sulphonate is used; (11) as (10) but also incorporating benzene sulphonhydrazide; (12) 40% m-cresol formaldehyde (prepared from a coal-tar fraction consisting of 40% m-cresol, 24% p-cresol, 17% o-cresol, 18% isomeric xylenols and 1% phenol) is mixed with benzene sulphonhydrazide p-toluene sulphonate; (13) a mixture of resorcinol formaldehyde, phenol formaldehyde, paraformaldehyde and benzene sulphonhydrazide acid sulphate is used; (14) a mixture of 53% m-cresol formaldehyde, phenol formaldehyde and benzene sulphonhydrazide acid sulphate is used.ALSO:Foamed resinous materials are prepared by mixing a liquid alkali-catalysed phnenolic condensate of formaldehyde in which the phenolic components consists of a methyl substituted monohydric phenol or mixture of such substituted phenols or a dihydric phenol carrying hydroxyl groups as sole substituents and which phenolic component may contain a minor amount (i.e. less than 50%) of phenol, with a sulphonhydrazide and an acid curing catalyst.  The condensate preferably has a viscosity of 10-100 poises at 25 DEG C.  The catalysts may be combined with the sulphonhydrazides to form salts which are then added to the condensate.  The foamed products may be used as packaging, insulating and reinforcing materials.  In the Examples: (1) and (2) a mixture of m-cresol formaldehyde, an alkyl phenol/ethylene oxide condensate and benzene sulphonhydrazide acid sulphate is used; (3) as (1) and )2) but also containing benzene sulphonhydrazide sulphate; (4) benzene sulphonhydrazide acid sulphate is added to a mixture of m-cresol formaldehyde and phenol formaldehyde; (5) 53% m-cresol formaldehyde (prepared from a coal-tar fraction containing 53% m-cresol, the remainder being p- and o-cresol and xylenols) is mixed with benzene sulphonhydrazide acid sulphate; (6) and (15) as (5) but also containing an alkyl phenol/ethylene oxide condensate and HC1; (7) a mixture of 53% m-cresol formaldehyde, an alkyl phenol/ethylene oxide condensate and p:p1-oxy-bis-(benzene sulphonhydrazide) acid sulphate is used; (8) phenol 53% m-croesl formaldehyde is mixed with benzene sulphonhydrazide acid sulphate; (9) as (8) but also incorporating an alkyl phenol/ethylene oxide condensate; (10) a mixture of phenol 53% m-cresol formaldehyde, an alkyl phenol/ethylene oxide condensate and benzene sulphonhydrazide p-toluene sulphonate is used; (11) as (10) but also incorporating benzene sulphonhydrazide; (12) 49% m-cresol formaldehyde (prepared from a coal-tar fraction consisting of 40% m-cresol, 24% p-cresol, 17% o-cresol, 18% isomeric xylenols and 1% phenol) is mixed with benzene sulphonhydrazide p-toluene sulphonate; (13) a mixture of resorcinol formaldehyde, phenol formaldehyde, paraformaldehyde and benzene sulphonhydrazide acid sulphate is use; (14) a mixture of 53% m-cresol formaldehyde, phenol formaldehyde and benzene sulphonhydrazide acid sulphate is used.